Compartmentalization system for industrial totes and compartmentalizable totes

ABSTRACT

A compartmentalization system for an industrial tote includes a base, side walls, which include recesses for retaining bins within the tote and end walls. The tote may include eight recesses in each side wall for receiving a pair of inserts on a bin. The bins typically include two or four tabs. The bins that are used with the tote system include a base opposed side walls and end walls that define the interior of the bin. Typically, a lip formed at the top of the side and end walls to improve strength and stability. The tabs are formed on the exterior of at least one side wall. The tab is inserted into the recess in the tote. Each tab includes a riser that is substantially normal to the sidewall and a tab formed at the end of the riser so that the tab is spaced apart from the sidewall.

CLAIM OF PRIORITY

This application is Continuation in Part of U.S. Application 61/557,168,filed Nov. 8, 2011 entitled “COMPARTMENTALIZATION SYSTEM FOR INDUSTRIALTOTES AND COMPARTMENTALIZABLE TOTES” and having Travis Shamp and AlbertKobilarcik as inventors. All aspects of Application 61/557,168 arehereby incorporated by reference.

BACKGROUND

Bins and bin systems are often used in industrial assembly. Often thebins filled with a number of parts and are moved along a conveyor fromone location to the next. A large installed base of conveyor systemsexists. The bins typically carry a single part or loose boxes of partsso that it is difficult to efficiently move parts through the conveyorsystem. Such bin conveyors are shown in U.S. Pat. No. 7,954,627 entitled“Bin Transporter System” showing Brian C. Weed et al. as inventors.Another patent showing such a conveyor system is U.S. Pat. No. 7,809,467entitled “System and Method for order Picking of Articles into OrderContainers” showing Gerhard Schaefer as inventor.

SUMMARY

In accordance with embodiments of the present invention, acompartmentalization system for industrial totes and compartmentalizedtotes and bins therefor are presented. The tote of the present inventioninclude a base, side walls, which include recesses for retaining binswithin the tote and end walls. As shown, the tote of the presentinvention includes a base, a first wall and a second side wall, each ofside walls including a plurality of recesses for retaining a bin insertwithin the tote; and first and second end walls, the base, side wallsand end walls defining a tote interior. Also disclosed is a bin for usein a compartmentalizable tote system, having a base; side walls; endwalls forming a bin interior and a tab formed on the exterior of atleast a first side wall, the tab being suitable for insertion into arecess formed in a first sidewall of a compartmentalizable tote system.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and the many embodimentsthereof will be readily obtained as the same becomes better understoodby reference to the following detailed description when considered inconnection with the accompanying drawings, wherein:

FIG. 1 illustrates an isometric view of the tote system with insertedbins of the present invention;

FIG. 1A illustrates an isometric, cross sectional view, in detail of theinserted bin retention system;

FIG. 2 illustrates an isometric view of the tote system of the presentinvention, without the inserted bins;

FIG. 2A illustrates a plan view of the tote system of the presentinvention, showing molded fixtures in the sidewall of the tote;

FIG. 3 illustrates an isometric view of bin inserts in accordance withthe present invention;

FIG. 3A illustrates a cross sectional view of a bin insert in accordancewith the present invention;

FIG. 3B illustrates a plan view of a bin insert in accordance with thepresent invention;

FIG. 3C illustrates an isometric view of a bin insert in accordance withthe present invention;

FIG. 3D illustrates an plan view of a bin insert in accordance with thepresent invention;

FIG. 3E illustrates an elevational view of a bin insert in accordancewith the present invention;

FIG. 4 illustrates an isometric view of a tote in an alternateembodiment of the present invention;

FIG. 5 illustrates an isometric view of the bottom of a tote in analternate embodiment of the present invention.

FIG. 6 illustrates an isometric view of a tote with dividers inserted inan alternate embodiment of the present invention.

FIG. 7 illustrates an isometric view of a tote in another alternateembodiment of the present invention.

FIG. 8 illustrates an isometric view of a tote with dividers inserted inan alternate embodiment of the present invention.

DETAILED DESCRIPTION

The present invention will now be described with occasional reference tothe specific embodiments of the invention. This invention may, however,be embodied in different forms and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments are providedso that this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The terminology used in thedescription of the invention herein is for describing particularembodiments only and is not intended to be limiting of the invention. Asused in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities ofingredients, properties such as molecular weight, reaction conditions,and so forth as used in the specification and claims are to beunderstood as being modified in all instances by the term “about.”Accordingly, unless otherwise indicated, the numerical properties setforth in the specification and claims are approximations that may varydepending on the desired properties sought to be obtained in embodimentsof the present invention. Notwithstanding that the numerical ranges andparameters setting forth the broad scope of the invention areapproximations, the numerical values set forth in the specific examplesare reported as precisely as possible. Any numerical values, however,inherently contain certain errors necessarily resulting from error foundin their respective measurements.

A compartmentalizable tote system is shown in FIG. 1 and FIG. 1A. Thetote system includes a tote and one or more bins that may be securedwithin the tote. As shown in FIG. 1 and FIG. 1A the tote system mayinclude a number of bins of different sizes and shapes. The bins aretypically secured within the tote by a tab system on the side walls. Asshown in FIG. 1, a tote 10 is provided with side walls 12 that maycontain, a half-sized bin insert 22, a quarter-size bin insert 26 andtwo eighth-size bin inserts 28. The bin inserts may optionally includehandles 24. The tote 10 may include a reinforcing rim 30 and a secondaryrim 30 a formed on the upper portion of sidewalls 12 and a lower rim 34.Also included on sidewalls 12 are vertical tote reinforcements 36 andrim reinforcements 32 as well as a lower rim 34. The various bin inserts22, 26, 28 may be used in any combination based on the needs of thefacility using the totes.

The bin insert retaining system is shown in FIG. 1A, first and secondtote sidewalls 12 include recesses for retaining bin inserts within thetote. The bin insert may include any number of recesses in each sidewall. Preferably, the recesses 50, 52 are paired so each pair ofrecesses receives a pair of inserts on a bin 28. A second type of recess64 may be provided for the insertion of divider walls (as shown in FIG.6). Bin insert 28 includes side walls 28 a, 28 b, 28 c, 28 d andsidewalls 28 a and 28 c may include stack ribs 54. Stack ribs 54 areprovided to inhibit the jamming of empty bin inserts 28 when stacked.The bin insert 28 also includes at least one retaining tab 50, 52 eachhaving a spacer 84 that displaces tab 50, 52 from sidewall 28 d of bininsert 28. While tabs 50, 52 are shown turning to opposite sides theytab 52 may be of any suitable configuration, such as toward the exteriorof the bin insert, toward the interior of the bin insert or spacer 84may be located toward the center of tabs 50, 52 so that no apparent leftor right turn is present. Tabs 50, 52 are received in slots 60, 62. Eachslot 60 includes a front wall 60 a, side wall 60 c, back wall 60 d anddistal wall 60 b. The walls 60 a, 60 b, 60 c and 60 d enclose slot 60,which receives the tab 50 while spacer 84 fits between front wall 60 aand side wall 60 c. Similarly, as shown walls 62 a, 62 b, 62 c and 62 dare formed in tote wall 12 to receive tab 52. A second configuration fora slot 64 in sidewall 12 a is shown in FIG. 1A in which the groove 64 isdefined by two front walls 60 a, side walls 60 b, 60 c and a back wall60 d. Reinforcing rim 30 and secondary rim 30 a formed on the upperportion of sidewalls 12 and rim reinforcements 32 provide a stiff andrugged tote for the bins.

The tote 10 is shown in FIG. 2, the tote includes sidewalls 12 havingrecesses 60, 62 for retaining bin inserts within the tote. The sidewalls12 and sidewalls 12 a include slots 64 for retaining dividers 94 (asshown in FIG. 6). The bin insert may include any number of recesses 60,62 or slots 64 in each side wall. Tote 10 includes reinforcing rim 30and secondary rims 30 a, 30 b formed on the upper portion of sidewalls12 and rim reinforcements 32 provide a stiff and rugged tote for thebins. Walls 12, 12 a are formed with vertical structural beams 36between upper rims 30, 30 a, 30 b, and lower rim 34. The base of thetote includes channels 64 that receive tote dividers. The base also mayinclude channel features 79 that define base sections 74 on which theinternal bins rest. Preferably the internal bins include a lower lipthat mates with the step down features 79 to inhibit movement of thebins within tote 10.

The side of tote 10 is shown in FIG. 2A. As with FIG. 2, the toteincludes sidewalls 12 having recesses 60, 62 for retaining bin insertswithin the tote. The sidewall 12 includes reinforcing rim 30 andsecondary rims 30 a, 30 b formed on the upper portion of sidewalls 12and rim reinforcements 32 and vertical structural beams 36 between upperrims 30, 30 a, 30 b, and lower rim 34. The base of tote 10 is typicallysmaller than the inner edge of the rim 30 so that multiple totes may bestacked vertically.

Three internal bins 22, 26, 28 are shown in FIG. 3. The bins 22, 26, 28typically include two or four tabs 50, 52 depending on the size of thebin. While it may be preferable to have tabs on opposite sides of halfsize bin 22 it is not necessary to maintain a stable fit. It is alsopossible to manufacture bins of any size and that included eight tabs ormore tabs. Typically at least one handle 24 is molded into the bins 22,26, 28.

FIG. 3A shows a bin 28 including base 28 c, side walls 28 a, 28 b andupper rim 80. The upper rim 80 and sidewall 28 a are integrally formedwith tab 50. Preferably, tab 50 is spaced apart from sidewall 28 a byspacer 84 and an upper reinforcement 82. The gap between tab 50 andsidewall 28 a is preferably slightly greater than the thickness of frontwall 62 a of slot 60 (as shown in FIG. 1A). The tab 50 is releasablyretained within slot 60.

As shown in FIG. 3B, the bin 28 may include base 28 c and side walls 28a, 28 b, 28 e, one or more handles 24 and one or more tabs 50, 52. Onesuitable shape for the tabs 50, 52 is trapezoidal. The trapezoidal shapebeing wider at the top and tapering to a narrower width at the bottomprovides for easier insertion of the bin and improved stability of thebin once installed. Each tab 50, 52 include may include a projection 50b and an arcuate section 50 a formed in rim 80 that form a stop so thattabs 50, 52 do not jam into their respective slots.

As shown in FIG. 3C, the bin 26 may include side walls 26 a, 26 b, 26 d,26 e, one or more handles 24 and one or more tabs 50, 52 formed in rim80. One suitable shape for the tabs 50, 52 is trapezoidal. The quartersize bin 26 will generally include two pairs of tabs 50, 52 for secureretention within the tote.

As shown in FIG. 3D, the quarter sized bin 26 may include side walls 26a, 26 b, 26 e, base 28 c, one or more handles 24 and one or more tabs50, 52 formed in rim 80. As discussed above, with respect to FIG. 3B,one suitable shape for the tabs 50, 52 is trapezoidal. Each tab 50, 52include may include a projection 50 b and an arcuate section 50 a formedin rim 80 that form a stop so that tabs 50, 52 do not jam into theirrespective slots. The use of two pairs of tabs 50, 52 provide sufficientstability when inserted. FIG. 3E shows a top view of bin 26 as shown inFIG. 3D, showing the position of handles 24 formed in rim 80 over tabs50, 52. Also shown is base 28 c.

An alternate embodiment of the tote 10 is shown in FIG. 4. The toteincludes sidewalls 12 having recesses 60, 62 for retaining bin insertswithin the tote. The sidewalls 12 and sidewalls 12 a include slots 64for retaining dividers 94 (as shown in FIG. 6). The bin insert mayinclude any number of recesses 60, 62 or slots 64 in each side wall.Tote 10 includes reinforcing rim 30 and secondary rims 30 a, 30 b withrim reinforcements 32 formed on the upper portion of sidewalls 12, 12 a.Rim reinforcements 32 interconnecting rims 30, 30 a, 30 b provide astiff and rugged tote for the bins. Slots 64 are formed in side wall 12as are rim reinforcing members 36. Walls 12, 12 a are formed withvertical structural beams 36 between upper rims 30, 30 a, 30 b, andlower rim 34. The base of the tote includes channels 64 that receivetote dividers and define base step down features 79 and base sections 74on which the internal bins rest.

FIG. 5 shows the alternate embodiment of the tote 10 as shown in FIG. 4.The tote includes sidewalls 12 having recesses 60, 62 for retaining bininserts within the tote. The sidewalls 12 and sidewalls 12 a includeslots 64 for retaining dividers 92, 94 (as shown in FIG. 6). The totemay include any number of recesses 60, 62 or slots 64 in each side wall.Tote 10 includes reinforcing rim 30 and secondary rims 30 a, 30 b withrim reinforcements 32 formed on the upper portion of sidewalls 12, 12 a.Slots 60, 62 are formed in side wall 12 as are rim reinforcing members36. Walls 12, 12 a are formed with vertical structural beams 36 betweenupper rims 30, 30 a, 30 b, and lower rim 34. The base of the toteincludes channels 64 that receive tote dividers and define base stepdown features 79 and base sections 74 on which the internal bins rest.Dividers 92, 94 are inserted into slots 64 to form a divided tote.

FIG. 6 shows the tote includes sidewalls 12 having recesses 60, 62 forretaining bin inserts within the tote. The sidewalls 12 and sidewalls 12a include slots 64 for retaining dividers 94. The bin insert may includeany number of recesses 60, 62 or slots 64 in each side wall. Tote 10includes reinforcing rim 30 and secondary rims 30 a, 30 b with rimreinforcements 32 formed on the upper portion of sidewalls 12, 12 a. Rimreinforcements 32 interconnecting rims 30, 30 a, 30 b provide a stiffand rugged tote for the bins. Slots 64 are formed in side wall 12 as arerim reinforcing members 36. Walls 12, 12 a are formed with verticalstructural beams 36 between upper rims 30, 30 a, 30 b, and lower rim 34.The base of the tote includes channels 64 that receive tote dividers anddefine base step down features 79 and base sections 74 on which theinternal bins rest.

Yet another embodiment of the invention is shown in FIG. 7 and FIG. 8 inwhich the tote 100 includes sidewalls 112 and sidewalls 112 a includeslots 164 for retaining dividers 180. The tote 100 may include anynumber of slots 164 in each side wall 112, 112 a. Tote 100 includesreinforcing rim 130 and secondary rims 130 a,130 b with rimreinforcements 132 formed on the upper portion of sidewalls 112, 112 a.Slots 164 are formed in side wall 112 as are rim reinforcing members132. Walls 112, 112 a are formed with vertical structural beams 136between upper rims 130, 130 a, 130 b, and lower rim 134. The base of thetote includes channels 164 that receive tote dividers 180, 182 anddefine base sections 174.

The totes and bins may be formed by any suitable method typicallythermoforming, injection molding, blow molding and rotocasting are usedfor totes and bins.

The present invention should not be considered limited to the specificexamples described herein, but rather should be understood to cover allaspects of the invention. Various modifications, equivalent processes,as well as numerous structures and devices to which the presentinvention may be applicable will be readily apparent to those of skillin the art. Those skilled in the art will understand that variouschanges may be made without departing from the scope of the invention,which is not to be considered limited to what is described in thespecification.

What is claimed is:
 1. A tote for a compartmentalization system,comprising: a base; first and second side walls, each of side wallsincluding a plurality of recesses for retaining a bin insert within thetote; and first and second end walls, the base, side walls and end wallsdefining a tote interior.
 2. The tote of claim 1, wherein each recesscomprises: a first side surface proximate the tote interior; a secondside surface distal to the tote interior; and edge surfaces between thefirst and second side surfaces, whereby the first and second sidesurfaces and the edge wall define the recess.
 3. The tote of claim 1,further comprising: a first side surface proximate the tote interior; asecond side surface distal to the tote interior; and edge surfacesbetween the first and second side surfaces, whereby the first and secondside surfaces and the edge wall define a generally trapezoidal recess.4. The tote of claim 3, further comprising: a channel in the first sidesurface proximate the tote interior; and edge surfaces between the firstand second side surfaces, whereby the first and second side surfaces andthe edge wall define the recess.
 5. The tote of claim 3, furthercomprising: a plurality of recesses in each side wall; and a pluralityof channels in the first side surface proximate the tote interior. 6.The tote of claim 3, wherein the recesses are tapered from top to bottomsuch that the bottom is narrower than the top.
 7. The tote of claim 3,wherein the recesses are generally trapezoidal.
 8. The tote of claim 3,further comprising: eight recesses in each side wall, the recesses beinggrouped in pairs such that each pair of recesses receives a pair ofinserts on a bin suitable for being received within the tote.
 9. Thetote of claim 1, wherein the tote is formed by a method selected fromthe group consisting of thermoforming, injection molding, blow moldingand rotocasting.
 10. A bin for use in a compartmentalizable tote system,comprising: a base; first and second side walls; first and second endwalls, the base, side walls and end walls defining a bin interior. a tabformed on the exterior of at least a first side wall, the tab beingsuitable for insertion into a recess formed in a first sidewall of acompartmentalizable tote system.
 11. The bin of claim 10, furthercomprising a lip formed at the top of the first sidewall.
 12. The bin ofclaim 10, further comprising a lip formed at the top of the side and endwalls.
 13. The bin of claim 10, wherein the tab comprises: a riser,substantially normal to the first sidewall; a tab section formed withthe riser and spaced apart from the first sidewall.
 14. The bin of claim13, wherein the tab section is tapered from the top portion to thebottom portion.
 15. The bin of claim 10, further comprising a pluralityof tabs, each tab comprising: a riser, substantially normal to the firstsidewall; a tab section formed with the riser and spaced apart from thefirst sidewall.
 16. The bin of claim 15, wherein the tab section isgenerally trapezoidal.
 17. A compartmentalizable tote and bin system,comprising: a tote having: a tote base; a first tote sidewall includinga plurality of recesses for retaining a bin insert within the tote; anda second tote sidewall; first and second tote end walls, the tote base,the tote side walls and tote end walls defining an tote interior; thefirst tote sidewall having an interior surface and an exterior surfacewith edge surfaces between the interior and exterior surfaces, defininga recess; and a bin having: a bin base; first and second bin side walls;first and second bin end walls, the bin base, bin side walls and bin endwalls defining a bin interior. at least one tab formed on the exteriorof at least a first bin side wall, the tab being suitable for insertioninto the tote recess.
 18. The compartmentalizable tote and bin system,of claim 17, wherein the tabs comprise: a riser, substantially normal tothe first sidewall; a trapezoidal tab section formed with the riser andspaced apart from the first sidewall.
 19. The compartmentalizable toteand bin system, of claim 17, further comprising a plurality of recesseseach having: a channel in the interior surface; and edge surfacesbetween the first and second side surfaces, whereby the first and secondside surfaces and the edge wall define a trapezoidal recess.
 20. Thecompartmentalizable tote and bin system of claim 17, wherein the secondtote sidewall includes a plurality of recesses for retaining a bininsert within the tote.